BadDog

I have a single wire alternator. Just had it rebuilt and second trip out it quit working. I was a bit pizzed until I lifted the hatch to investigate and found that the ring terminal had broken off. It looks like a clean break at the stamping line. Bought them at some auto parts store and the box said made in China. Low quality part. Anyway what that means is that it was just like switching the batteries to off with the engine running. Alternator spinning with no place for the power to go. Batteries were very low so perhaps it was making a large amount of current causing the ring terminal to get warm thus speeding it demise.

So, does spinning an alternator without a positive connection kill it? I need to select a little higher quality component this time around.

stevesxm

no. and if you used thomas and betts connectors ( and they make a hd version as well) youll be fine. what i have always done is put a small blob of red silicone on all those connections after they are installed... it acts both as a lock and also damps out the vibration that causes the type of failure you had...

but the alt should be fine.

Edward R. Cozzi

I agree with Steve. That wire breaking off should not have spiked the voltage that damages the internals.

BadDog

OK, then the connection cracking did not kill the alternator, just a coincidence that it happend at roughly the same time. I need to check for vibration and strain relief the 2 gauge wire better as well as use a better quality connector. Back to the alternator shop.

stevesxm

strain relief is easy... crimp, solder and heatshrink... w/ a good electronic heat shrink... not radio shack... on mine i used a heat shrink that actually has an adhesive inside.... once on its forever.